Cooling tower support grid

ABSTRACT

A cooling tower support grid includes a lattice frame having a first series of bars which intersect a second series of bars to form a plurality of openings. Splash bar retaining clips are integrally formed as part of the lattice frame extending in opposed relation into each of the openings. This eliminates the need to handle separate retaining clips and, thereby, simplifies the installation process.

This application is a Reissue of application Ser. No. 09/902,090, filedJul. 10, 2001, and issued as U.S. Pat. No. 6,708,960 on Mar. 23, 2004.

FIELD OF THE INVENTION

The present invention relates to a cooling tower support grid forsupporting splash bars.

BACKGROUND OF THE INVENTION

Cooling tower support grids are used to support splash bars which spanacross a cooling tower, so that the splash bars do not sag. The splashbars are offset both vertically and horizontally, so that water dropletsfalling vertically from near the top of the cooling tower willinvariably strike one or more of the splash bars during descent. Largewater droplets are broken into smaller water droplets upon striking oneof the splash bars. As many water droplets strike the splash bars, athin film of water tends to form on each splash bar which increases thesurface area of water exposed to air.

There is a tendency for splash bars to become dislodged due toimpingement by water from above, forced air flow from below andvibration caused by fans used to circulate air within the cooling tower.To guard against the splash bars becoming dislodged, the splash bars arecommonly secured to the support grid by clips.

An example of a support grid is U.S. Pat. No. 4,178,333 (Shepherd).Examples of splash bars are U.S. Pat. No. 4,663,092 (Kinney Jr. et al)and U.S. Pat. No. 5,454,987 (Cornwell Jr.). Examples of clips are U.S.Pat. No. 4,774,034 (Fritz) and U.S. Pat. No. 4,868,956 (Shepherd).

SUMMARY OF THE INVENTION

The present invention relates to an alternative configuration for acooling tower support grid.

According to the present invention there is provided a cooling towersupport grid which includes a lattice frame having a first series ofbars which intersect a second series of bars to form a plurality ofopenings. Splash bar retaining clips are integrally formed as part ofthe lattice frame extending in opposed relation into each of theopenings.

The cooling tower support grid, as described above, turns what formerlywas a three component system consisting of support grid, splash bars andclips into a two component system. The need to handle clips iseliminated as they are integrally formed as part of the support grid.There are a variety of suitable moldable materials that can be used.Beneficial results have been obtained by injection molding polymerplastic.

The lattice frame can be made in a various configurations. Beneficialresults have been obtained when the first series of bars are in parallelspaced relation and the second series of bars are in parallel spacedrelation.

The type of clips used depends upon which of a variety of alternativeconfigurations of splash bars are to be used with the support grid.Beneficial results have been obtained when the clips have a resilientfinger. It is preferred that the resilient finger be angled upwardly andterminate in a downwardly bent portion.

The clips are more versatile and can be used with a wider variety ofsplash bar configurations, as will hereinafter be further described,when the clips have a lower retainer. Beneficial results have beobtained through the use of a retainer lip.

The positioning of the clips within the openings can be varied to suitalternative splash bar configurations. Beneficial results have beenobtained when each of the clips extends from one of the first series ofbars above and immediately adjacent to one of the second series of bars.

It is desirable that the support grid be rapidly and easily installed ina cooling tower. Even more beneficial results have been obtained when anupper peripheral edge of the lattice frame has an integrally formed hookwhereby the lattice frame is suspended to facilitate rapid installation.It is preferred that a lower peripheral edge of the lattice frame havedepending tabs with openings, whereby the lattice frame is secured inposition by extending fasteners through the openings.

The clips on the lattice frame of the cooling tower support grid mustengage a plurality of cooling tower splash bars. It is preferred thateach of the splash bars include a elongate channel-form body having afirst end, a second end, and a plurality of flow-through apertures. Thedownwardly bent portion of the resilient finger engaging one of theplurality of flow-through apertures.

Although beneficial results may be obtained through the use of thesplash bars, as described above, even more beneficial results may beobtained when the body has a first longitudinal edge and a secondlongitudinal edge; with both the first longitudinal edge and the secondlongitudinal edge having outwardly protruding engagement lips. Thisenables the engagement lips to be positioned between opposed ones of thelower retainer lips and the one of the second series of bars immediatelyadjacent to the clips.

Although there are various configurations of channel-form bodies thatcould be used, it is preferred that the bodies form a “C” channel. Thereason is that this enables the bodies to be used individually as an“open” channel or put together in face to face relation as a “closed”channel.

When the “C” channel splash bars are going to be used in face to facerelation, it is preferred that several male members to be positionedalong the first longitudinal edge and several female receptacles bepositioned along the second longitudinal edge. This enables a pair ofbodies to be secured in face to face relation by inserting the severalmale members of each of the pair of bodies into the several femalereceptacles of the other of the pair of bodies.

Cooling towers come in a different width dimensions. Even morebeneficial results may, therefore, be obtained when the first end ofeach body has male members and the second end of each body has femalemembers adapted to receive in mating relation the male members. Thisenables several of the bodies to be joined in end to end relation tocreate a splash bar of a length that is suited to the width of thecooling tower. There can be any number of male members. Of course,several spaced male members will provide a more uniform hold than asingle male member can provide. Beneficial results have been obtainedthrough the use of three male members: a first male member protrudingfrom the first longitudinal edge, a second male member protruding fromthe second longitudinal edge and a third male member positionedintermediate the first male member and the second male member.

It would be undesirable for splash bars joined in end to end relation toseparate. It is, therefore, preferred that each of the male membersterminates in an engagement member and each of the female membersterminates in a locking recess adapted to receive the engagement member.This structure provides a locking engagement whereby each of the malemembers remains engaged with the female members until sufficient forceis applied to cause the engagement member to be released from thelocking recess.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will become more apparent fromthe following description in which reference is made to the appendeddrawings, the drawings are for the purpose of illustration only and arenot intended to in any way limit the scope of the invention to theparticular embodiment or embodiments shown, wherein:

FIG. 1 is front elevation view of a cooling tower support gridconstructed in accordance with the teachings of the present invention.

FIG. 2 is a perspective view of a cooling tower splash bar constructedin accordance with the teachings of the present invention.

FIG. 3 is a side elevation view of the cooling tower splash barillustrated in FIG. 2.

FIG. 4 is a bottom plan view of the cooling tower splash bar illustratedin FIG. 2.

FIG. 5 is a detailed perspective view a first end of the cooling towersplash bar illustrated in FIG. 2, depicting male members.

FIG. 6 is a detailed perspective view of the cooling tower splash barillustrated in FIG. 2, depicting female members.

FIG. 7 is a detailed front elevation view of the cooling tower supportgrid illustrated in FIG. 1, engaged with two alternative configurationsof splash bar.

FIG. 8 is a detailed perspective view of the cooling tower support gridillustrated in FIG. 1, engaged with an open channel splash bar.

FIG. 9 is a detailed perspective view of the cooling tower support gridillustrated in FIG. 1, engaged with a closed channel splash bar.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment, a cooling tower support grid generallyidentified by reference numeral 10, will now be described with referenceto FIGS. 1 through 9.

Structure and Relationship of Parts

Referring to FIG. 1, there is provided a cooling tower support grid 10which includes a lattice frame 12 that has a first series of parallelbars 14 which intersect with a second series of parallel bars 16 to forma plurality of openings 18. Splash bar retaining clips 20 are integrallyformed as part of lattice frame 12. Retaining clips 20 extend in opposedrelation into each of openings 18. Each clip 20 extends from one offirst series of bars 14 above and immediately adjacent to one of secondseries of bars 16. Referring to FIG. 7, each clip 20 has a lowerretainer lip 22 and a resilient finger 24 which is angled upwardly andterminates in a downwardly bent portion 26.

Referring to FIG. 8, an upper peripheral edge 28 of lattice frame 12 hasan integrally formed hook 30 whereby lattice frame 12 is suspended.Referring to FIG. 1, a lower peripheral edge 32 of lattice frame 12 hasdepending tabs 34 with openings 36 whereby lattice frame 12 is securedin position by extending fasteners such as nails 38 through openings 36.

Referring to FIG. 7, a plurality of cooling tower splash bars 40 arearranged on lattice frame 12. Referring to FIGS. 2, 3, and 4, eachsplash bar 40 includes an elongate “C” channel body 42 that has a firstend 44, a second end 46, a first longitudinal edge 48, a secondlongitudinal edge 50 and a plurality of flow-through apertures 52. Bothfirst longitudinal edge 48 and second longitudinal edge 50 haveoutwardly protruding engagement lips 54. Referring to FIG. 3, malemembers 56 are positioned along first longitudinal edge 48. Referring toFIG. 4, female receptacles 58 are positioned along second longitudinaledge 50.

Referring to FIG. 7, cooling tower splash bars 40 can be arranged ineither an individually as an “open” channel 60 or alternatively, coolingtower splash bars 40 can be placed together in face to face relation asa “closed” channel 62. Referring to FIG. 8, to place splash bar 40 as an“open” channel 60, engagement lips 54 are positioned between opposedlower retainer lips 22 and one of second series of bars 16 immediatelyadjacent to clips 20 with downwardly bent portion 26 of each resilientfinger 24 engaging one flow-through apertures 52. Referring to FIGS. 3,4, 7 and 9, in order to assemble a “closed” channel 62, two of bodies 42are secured in face to face relation by inserting male members 56 ofeach body 42 into female receptacles 58 of other body 42. Downwardlybent portion 26 of resilient fingers 24 engage flow-through apertures 52to hold bodies 42 in position.

Referring to FIG. 5, first end 44 of each body 42 has a first malemember 64 protruding from first longitudinal edge 48, a second malemember 66 protruding from second longitudinal edge 50 and a third malemember 68 positioned intermediate first male member 64 and second malemember 66. It will be appreciated, however, that there can by any numberof male members. Referring to FIG. 6, second end 46 of each body 42 hasfemale members 70 that are adapted to receive in mating relation firstmale member 64, second male member 66, and third male member 68 so thatseveral bodies 42 can be joined in end to end relation. Referring toFIG. 5, each of first male member 64, second male member 66, and thirdmale member 68 terminate in an engagement member 72. Referring to FIGS.4 and 6, each of female members 70 terminate in a locking recess 74adapted to receive engagement member 72 of each of first male member 64,second male member 66 and third male member 68 such that they willremain engaged with female members 70.

Operation

The use and operation of cooling tower support grid 10 will now bedescribed with reference to FIGS. 1 through 9. Referring to FIGS. 1 and7, cooling tower support grids 10 are used to support splash bars 40.Support grids 10 are spaced across a cooling tower so that splash bars40 do not sag. Splash bars are offset both vertically and horizontallyon support grid 10, so that falling water droplets will invariablystrike one or more of splash bars 40 during descent. As many waterdroplets strike splash bars 40, a thin film of water tends to form oneach splash bar 40 which increases the surface area of water exposed toair.

Referring to FIGS. 1 and 8, hook 30 on upper peripheral edge 28 ofsupport grid 10 and depending tabs 34 on lower peripheral edge 32 ofsupport grid 10 allow for support grid 10 to be rapidly and easilyinstalled in a cooling tower. Referring to FIG. 7, clips 20 are used toprevent splash bars 40 from becoming dislodged from support grid 10 dueto impingement by water from above, forced air flow from below, orvibration cause by fans used to circulate air. As clips 20 areintegrally formed as part of lattice frame 12, the need to handle looseclips 20 is eliminated.

Clips 20 allow for several alternative configurations of splash bars 40.For example, bodies 42 can be used individually to form an “open”channel 60. Alternatively, bodies 42 can be placed together in face toface relation as a “closed” channel 62. Referring to FIGS. 4 and 9, whenplaced in face to face relation, male members 56 of each body 42 areinserted into female receptacles 58 of other body 42.

To accommodate cooling towers of a variety of widths, bodies 42 ofsplash bars 40 are adapted to be joined in end to end relation to createsplash bars 40 of a length that is suited for the width of a coolingtower. Referring to FIGS. 5 and 6, female members 70 at second end 46 ofeach body 42 are adapted to receive first male member 64, second malemember 66 and third male member 68 on first end 44 of each body 42 forthe purpose of securing bodies 42 in end to end relation. In theillustrated embodiment, three male members are provided, however it willbe appreciated that any number of male members will work. It will alsobe appreciated that several spaced male members will provide a moreuniform hold than a single male member could provide.

In order to prevent splash bars 40 that are joined in end to endrelation from separating, locking recess 74 is provided in femalemembers 70 that is adapted to receive engagement members 72 of firstmale member 64, second male member 66, and third male member 68 so thatthey remain engaged with female members 70 until sufficient force isapplied to cause engagement member 72 to be released from locking recess74.

Referring to FIG. 7, as a result, support grid 10, as described above,is quite versatile as it can be quickly and easily installed, and cansupport splash bars 40 in a variety of configurations.

Although in the illustrated embodiment, clips 20 are positionedimmediately adjacent to and above bars 16, the positioning of clips 20within openings 18 can be varied if alternative configurations of splashbar are used.

In this patent document, the word “comprising” is used in itsnon-limiting sense to mean that items following the word are included,but items not specifically mentioned are not excluded. A reference to anelement by the indefinite article “a” does not exclude the possibilitythat more than one of the element is present, unless the context clearlyrequires that there be one and only one of the elements.

It will be apparent to one skilled in the art that modifications may bemade to the illustrated embodiment without departing from the spirit andscope of the invention as hereinafter defined in the claims.

1. A cooling tower support grid, comprising: a lattice frame having afirst series of bars which intersect a second series of bars to form aplurality of openings; splash bar retaining clips integrally formed aspart of the lattice frame extending in opposed relation into each of theopenings.
 2. The cooling tower support grid as defined in claim 1,wherein the first series of bars are in parallel spaced relation and thesecond series of bars are in parallel spaced relation.
 3. The coolingtower support grid as defined in claim 1, wherein the clips have a lowerretainer.
 4. The cooling tower support grid as defined in claim 3,wherein the lower retainer is a lip.
 5. The cooling tower support gridas defined in claim 1, wherein each of the clips extends from one of thefirst series of bars above and immediately adjacent to one of the secondseries of bars.
 6. The cooling tower support grid as defined in claim 1,wherein an upper peripheral edge of the lattice frame has an integrallyformed hook whereby the lattice frame is suspended.
 7. A cooling towersupport grid, comprising: a lattice frame having a first series ofparallel bars which intersect a second series of parallel bars to form aplurality of openings; splash bar retaining clips integrally formed aspart of the lattice frame extending in opposed relation into each of theopenings two laterally adjacent openings of the lattice frame, each ofthe clips extending from one of the first series of bars above andimmediately adjacent to one of the second series of bars, each of theclips having a lower retainer lip and a resilient finger which is angledupwardly and terminates in a downwardly bent portion.
 8. The coolingtower support grid as defined in claim 7, wherein an upper peripheraledge of the lattice frame has an integrally formed hook whereby thelattice frame is suspended.
 9. The cooling tower support grid as definedin claim 7, wherein a lower peripheral edge of the lattice frame hasdepending tabs with openings whereby the lattice frame is secured inposition by extending fasteners through the openings.
 10. The coolingtower support grid as defined in claim 7, wherein the lattice frame iscombined with a plurality of cooling tower splash bars, each of thesplash bars comprising: an elongate channel-form body having a firstend, a second end, and a plurality of flow-through apertures; thedownwardly bent portion of the resilient finger engaging one of theplurality of flow-through apertures.
 11. The cooling tower support gridas defined in claim 10, wherein the body has a first longitudinal edgeand a second longitudinal edge, both the first longitudinal edge and thesecond longitudinal edge having outwardly protruding engagement lips.12. The cooling tower support grid as defined in claim 11, wherein theengagement lips are positioned between opposed ones of the lowerretainer lips and the one of the second series of bars immediatelyadjacent to the clips.
 13. The cooling tower support grid as defined inclaim 10, wherein the body is a “C” channel.
 14. The cooling towersupport grid as defined in claim 10, wherein the first end of each bodyhas male members and the second end of each body has female membersadapted to receive in mating relation the male members whereby severalof the bodies can be joined in end to end relation.
 15. The coolingtower support grid as defined in claim 14, wherein each of the malemembers terminates in an engagement member and each of the femalemembers terminates in a locking recess adapted to receive the engagementmember, whereby each of the male members remain engaged with the femalemembers until sufficient force is applied to cause the engagement memberto be released from the locking recess.
 16. The cooling tower supportgrid as defined in claim 11, wherein several male members are positionedalong the first longitudinal edge and several female receptacles arepositioned along the second longitudinal edge, whereby a pair of bodiescan be secured in face to face relation by inserting the male members ofeach of the pair of bodies into the female receptacles of the other ofthe pair of bodies.
 17. The cooling tower support grid as defined inclaim 7, wherein the lattice frame is combined with a plurality ofcooling tower splash bars, each of the splash bars comprising: anelongate “C” channel body having a first end, a second end, a firstlongitudinal edge, a second longitudinal edge and a plurality offlow-through apertures, both the first longitudinal edge and the secondlongitudinal edge having outwardly protruding engagement lips; theengagement lips being positioned between opposed ones of the lowerretainer lips and the one of the second series of bars immediatelyadjacent to the clips, with the downwardly bent portion of each of theresilient fingers engaging one of the plurality of flow-throughapertures.
 18. The cooling tower support grid as defined in claim 7,wherein the lattice frame is combined with a plurality of cooling towersplash bars, each of the splash bars comprising: an elongate “C” channelbody having a first end, a second end, a first longitudinal edge, asecond longitudinal edge and a plurality of flow-through apertures,several male members being positioned along the first longitudinal edgeand several female members being positioned along the secondlongitudinal edge; a pair of bodies secured in face to face relation byinserting the male members of each of the pair of bodies into the femalereceptacles of the other of the pair of bodies, the downwardly bentportion of each of the resilient fingers engaging one of the pluralityof flow-through apertures to hold the pair of bodies in position. 19.The cooling tower support grid as defined in claim 17, wherein the firstend of each body has male members and the second end of each body hasfemale members adapted to receive in mating relation the male memberswhereby several of the bodies can be joined in end to end relation. 20.The cooling tower support grid as defined in claim 19, wherein each ofthe male members terminates in an engagement member and each of thefemale members terminates in a locking recess adapted to receive theengagement member, whereby each of the male members remain engaged withthe female members until sufficient force is applied to cause theengagement member to be released from the locking recess.
 21. Thecooling tower support grid as defined in claim 14, wherein the body hasa first longitudinal edge and a second longitudinal edge and there arethree male members: a first male member protruding from the firstlongitudinal edge, a second male member protruding from the secondlongitudinal edge and a third male member positioned intermediate thefirst male member and the second male member.
 22. The cooling towersupport grid as defined in claim 21, wherein each of the male membersterminates in an engagement member and each of the female membersterminates in a locking recess adapted to receive the engagement member,whereby each of the male members remain engaged with the female membersuntil sufficient force is applied to cause the engagement member to bereleased from the locking recess.
 23. A cooling tower support grid,comprising: a lattice frame having a first series of bars whichintersect a second series of bars to form a plurality of openings;splash bar retaining clips integrally formed as part of the latticeframe, the retaining clips being placed into at least two laterallyspaced openings of the lattice frame; and each of the retaining clipshaving an engaging portion extended from the lattice frame, the engagingportion adapted to engage the splash bar to selectively secure thesplash bar against the lattice frame, in which the engaging portion isextended from the lattice frame by an extending member to extend theengaging portion from one of the second series of bars, in which theengaging portion comprises a resilient finger angled upwardly.
 24. Thecooling tower support grid of claim 23 or 28, in which the resilientfinger further comprises a downwardly bent portion.
 25. A cooling towersupport grid, comprising: a lattice frame having a first series of barswhich at least substantially perpendicularly intersect a second seriesof bars to form a plurality of openings; and splash bar retaining clipsintegrally formed as part of the lattice frame, the retaining clipsbeing placed into two laterally adjacent openings of the lattice frame,each of the retaining clips having a downward portion, the downwardportion adapted to engage the splash bar to selectively secure thesplash bar against the lattice frame, in which each of the splash barretaining clips further comprises a resilient finger angled upwardly andterminating in the downward portion.
 26. The cooling tower support gridof claim 25 in which each of the splash bar retaining clips is bent toform the downward portion.
 27. A cooling tower support grid forsupporting at least one splash bar, comprising: a lattice frame having aplurality of substantially rectangular openings formed between a firstseries of parallel bars and a second series of parallel bars; and asplash bar retaining clip within one of the openings, the splash barretaining clip having a first portion and a second downwardly-angledportion, the second downwardly-angled portion being positioned away fromthe lattice frame by the first portion, the second downwardly-angledportion adapted to engage the splash bar to selectively secure thesplash bar against one of the second series of parallel bars within thelattice frame, wherein the retaining clip is integrally formed with theframe to eliminate a need to handle the clip during operation, in whichthe first portion of the retaining clip is resilient, in which the firstportion comprises a resilient finger angled upwardly, and the downwardlyangled portion is a downwardly bent portion.
 28. A cooling tower supportgrid, comprising: a lattice frame having a first series of bars whichintersect a second series of bars to form a plurality of openings;splash bar retaining clips integrally formed as part of the latticeframe the retaining clips being placed into at least two laterallyspaced openings of the lattice frame, and; each of the retaining clipshaving an engaging portion extended from the lattice frame, the engagingportion adapted to engage the splash bar to selectively secure thesplash bar against the lattice frame, in which the engaging portionincludes a downwardly facing portion, and in which the engaging portioncomprises a resilient finger angled upwardly.